Abrasive article and method of use

ABSTRACT

A coated abrasive article (10) having a backing (12) and an abrasive coat (20) attached to the backing (12), the abrasive coat (20) comprising a cured abrasive slurry containing a plurality of abrasives particles, wherein the abrasive slurry is soluble such that it retains the abrasive particles on the backing (12) when in its solid state, and releases the abrasive particles from the backing (12) during the process of dissolution to a dissolved state.

The present invention relates to abrasive articles and methods of using the same for polishing. More particularly, it relates to an abrasive article having a water-activated polishing compound.

The preparation of automotive paint surfaces following repair after accident or other damage typically involves a multistage process. This process is initiated by de-nibbing the paint applied to the surface during the repair with a relatively coarse P1500 abrasive disc. The de-nibbed surface is then refined using a series of increasingly fine grade abrasive discs (typically P3000 and P6000), followed by a cutting compound and finally a polish.

As a result it is common for the operative to have to change the abrasive disk multiple times during the paint rectification process. This adds complexity and cost to the process as time is spent changing tooling rather than working on the surface to be repaired.

It is an object of the invention to at least mitigate some of the problems set out above.

According to a first aspect of the invention there is provided a coated abrasive article having

-   -   a backing and an abrasive coat attached to the backing,     -   the abrasive coat comprising a cured abrasive slurry containing         a plurality of abrasives particles,

wherein the abrasive slurry is soluble such that it retains the abrasive particles on the backing when in a solid state, and releases the abrasive particles from the backing during the process of dissolution to a dissolved state.

This aspect of the invention delivers advantages as follows. When the abrasive slurry is in its dry state, the article is able to deliver a high cut rate due to the surface texture of the cured abrasive slurry abrading the paint surface. However, when the abrasive slurry is in its dissolved state, the surface texture of the slurry breaks down reducing the aggressiveness of the abrasive thereby allowing the article to deliver a high finish to the paint surface. This is advantageous since the only action required by the user to initiate the change in state is to add liquid, for example water. No change of abrasive article or other tooling is required. This eliminates the need for the user to implement multiple abrasive changes to remove dust nibs and restore paint to its original finish.

A further significant advantage is that the requirement for a separate liquid polishing compound is eliminated. As the abrasive coat dissolves it forms a polishing compound which would otherwise have to be added to the abrasive disc by the user. In the present invention, the abrasive article can be used in its wet state to polish a substrate simply by mounting the disc on the sander and adding water.

Preferably, the cured slurry is attached to the backing by a liquid-softenable tie coat.

Advantageously, a liquid softenable tie coat improves the ability of the abrasive article to deliver high cut in its solid state and high finish in its dissolved state. The ability of the tie coat to soften when wet allows the abrasive article to assume a degree of conformability when wet. This conformability reduces the aggressiveness of the cut and allows an improved polishing action as the article is able more readily to conform to the surface of the paint finish. This is particularly advantageous given that the surface will frequently have a curved profile.

Preferably, the tie coat is a hydrogel.

Preferably, the backing is flexible when wet.

The provision of a flexible backing further promotes the conformability of the abrasive article when wet. This flexible backing acts in concert with the water-softenable tie coat to allow the article to conform to the profile of the paint surface to further improve finish.

Preferably, the backing is a non-woven web or foam.

More preferably, the backing is a thermoplastic web.

Preferably, the abrasive slurry is a UV light cured abrasive slurry.

Preferably, the abrasive slurry contains an acrylol morpholine oxide UV-curable monomer.

Advantageously, during UV-curing, the monomer forms a linear polymer which maintains its structural rigidity allowing surface features to be cured in the surface of the abrasive article which assist in delivering high cut when the abrasive article is in its dry state. Particularly advantageously, the linear polymer dissolves in water allowing the abrasive coat to dissolve into a polishing compound upon addition of water by the user.

Preferably, the abrasive slurry dissolves into a polishing compound upon dissolution by a liquid.

Preferably, the liquid is a surfactant or emulsion or, more preferably, water.

Preferably, the cured undissolved slurry has a surface texture comprising geometric forms.

More preferably, the cured undissolved slurry has a surface texture comprising polygons.

Preferably, the abrasive particles are formed of vermiculite.

According to a first aspect of the invention there is provided a method of abrading a work piece, the method including the steps of:

-   -   providing a coated abrasive article having     -   a backing and an abrasive coat attached to the backing,     -   the abrasive coat comprising a cured abrasive slurry containing         a plurality of abrasives particles,

wherein the abrasive slurry is soluble such that it retains the abrasive particles on the backing when in its solid state, and releases the abrasive particles from the backing during the process of dissolution to a dissolved state.

-   -   the method including the further steps of:     -   applying a liquid to the article to dissolve abrasive slurry in         order to release the abrasives particles from the backing to         form a polishing compound,     -   polishing the work piece with the backing and polishing         compound.         Preferably, the method includes the step of:     -   abrading the work piece with the article in a dry state prior to         adding the liquid.

The invention will now be described, by way of example only, with reference to FIG. 1 which shows a cross-section through an abrasive article of the present invention.

FIG. 1 shows an abrasive article in the form of an abrasive disc 10. The disc 10 is suitable for mounting on a rotary polisher or random orbital sander although it is conceivable within the scope of the invention that the abrasive article could be used for other forms of abrasive work. The disc 10 has a backing 12 with first and second opposed major surfaces 14, 16. The first major surface 14 carries a tie coat 18. An abrasive coat 20 is positioned on the tie coat 18.

The backing 12 is formed of a non-woven thermoplastic web comprising an open, lofty, three-dimensional structure of fibers bonded to one another at their mutual contact points. Such non-woven backings are well known in the art. In an alternative embodiment the backing 12 is a foam backing and other forms of backing are conceivable within the scope of the invention. The backing material, whether non-woven or foam, is flexible so as to offer a degree of compliance to the abrasive disc 10 when wet as will be described in further detail below.

Whilst the tie coat 18 is an optional feature of the invention, in the preferred embodiment of the invention it serves two principal purposes. Firstly, it improves the adhesion of the abrasive coat 20 to the backing and secondly it provides a degree of control over the rigidity of the backing 12. As described above, the backing 12 is inherently flexible. However, the process of UV-curing the tie coat 18 on the backing hardens the tie coat 18 which then maintains the backing 12 in a rigid state despite its inherent flexibility. This rigidity is maintained until such time as the tie coat 18 comes into contact with water (or other liquid such as an emulsion or surfactant) at which point the tie coat 18 softens. This has two effects. Firstly, the tie coat 18 no longer maintains the backing 12 in a rigid state allowing the adhesive disc 10 to adopt a degree of compliance. This reduces the aggression of the cut of the abrasive disc 10. Secondly, the tie coat permits a degree of movement in the abrasive coat 20 which further reduces the aggression of the cut.

The tie coat 18 contains an acrylol morpholine oxide UV-curable monomer which has a high glass transition temperature, is very hard when dry but is water-soluble in its cured linear polymer form. This solubility allows the tie coat 18 (and thereby the backing 12 to which the tie coat 18 is adhered) to transition from rigid when dry to flexible when wet.

The abrasive coat 20 is formed of a UV-curable abrasive slurry which contains a plurality of abrasive particles. The abrasive particles in this embodiment are Alumina 5 μm or Alumina 14 μm although other suitable minerals fall within the scope of the invention. The slurry is cast into a micro-replicated tooling to form a structured abrasive once cured. This process generates a geometric surface texture on the abrasive article in the form of polygons 22. When the abrasive disc 10 is dry, the abrasive coat 20 (by way of the polygons 22) delivers aggressive cut as the tips of the polygons abrade the workpiece.

However, the abrasive slurry, like the tie coat 18 described above, contains acrylol morpholine oxide (also referred to as ACMO) which enables the abrasive slurry to dissolve upon contact with water. Thus, the addition of water to the abrasive disc 10 causes the aggressive polygons to soften and break up. This reduces the cut of the abrasive article and increases the finish. As the dissolution continues the small abrasive particles (Alumina in the range of 5 to 14 um) are freed resulting in the abrasive slurry dissolving into a polishing compound which delivers a high finish to the workpiece.

TIE COAT FORMULATION EXAMPLE

Component % age by Weight ACMO 83.6 SR-246 1.2 TPO-L 2.8 OX-50 12.6 Total 100

ABRASIVE COAT FORMULATION EXAMPLE 1

50% 5 um mix (% Addition age by order Weight) Notes Isopar V A 11.3 Hydrocarbon Solvent to assist cut lubrication Drakesol 305 A Hydrocarbon Solvent to assist cut lubrication M120 lauryl B 1.7 Assists the formulation of micelles acrylate ACMO E 30.9 Acrylol morpholine oxide soluble monomer Byk UV-3500 D 0.4 Oil emulsifier to promote mineral dispersal Byk W985 F 4.3 Oil emulsifier to promote mineral dispersal Alumina 5 μm G 49.8 Abrasive Mineral TPO-L H 1 Catalyst for UV curing R812 fumed C 0.7 Thickener for solvent to promote silica stabilization of micelles Total 100

ABRASIVE COAT FORMULATION EXAMPLE 2

Addition 50% 14 um mix order (% age by Weight) Notes Isopar V A 11.2 Hydrocarbon Solvent to assist cut lubrication Drakesol A Hydrocarbon Solvent to assist cut lubrication 305 M120 lauryl B 1.7 Assists the formulation of micelles acrylate ACMO E 30.6 Acrylol morpholine oxide soluble monomer Byk UV- D 0.4 Oil emulsifier to promote mineral dispersal 3500 Byk W985 F 5.1 Oil emulsifier to promote mineral dispersal Alumina 14 μm G 49.1 Abrasive Mineral TPO-L H 0.05 Catalyst for UV curing R812 C 0.04 Thickener for solvent to promote stabilization of fumed silica micelles Total 100 Curing was achieved in a two stage process with the tie coat being cured before application and curing of the abrasive slurry. 

1. A coated abrasive article having a backing and an abrasive coat attached to the backing, the abrasive coat comprising a cured abrasive slurry containing a plurality of abrasives particles, wherein the abrasive slurry is soluble such that it retains the abrasive particles on the backing when in its solid state, and releases the abrasive particles from the backing during the process of dissolution to a dissolved state.
 2. The article of claim 1 wherein the cured slurry is attached to the backing by a liquid-softenable tie coat.
 3. The article of claim 2 wherein the tie coat is a hydrogel.
 4. The article of claim 1 wherein the backing is flexible when wet.
 5. The article of claim 4 wherein the backing is a non-woven web or foam.
 6. The article of claim 5 wherein the backing is a thermoplastic web.
 7. The article of claim 1 wherein the abrasive slurry is a UV light cured abrasive slurry.
 8. The article of claim 1 wherein the abrasive slurry contains an acrylol morpholine oxide UV-curable monomer.
 9. The article of claim 1 wherein the slurry dissolves into a polishing compound upon activation by fluid.
 10. The article of claim 9 wherein the fluid is water.
 11. The article of claim 1 wherein the cured undissolved slurry has a surface texture comprising geometric forms.
 12. The article of claim 11 wherein the geometric forms are polygons.
 13. The article of claim 1 wherein the abrasive particles are formed of vermiculite.
 14. A method of abrading a work piece, the method including the steps of: providing a coated abrasive article having a backing and an abrasive coat attached to the backing, the abrasive coat comprising a cured abrasive slurry containing a plurality of abrasives particles, wherein the abrasive slurry is soluble such that it retains the abrasive particles on the backing when in its solid state, and releases the abrasive particles from the backing during the process of dissolution to a dissolved state. the method including the further steps of: applying a liquid to the article to dissolve abrasive slurry in order to release the abrasives particles from the backing to form a polishing compound, polishing the work piece with the backing and polishing compound.
 15. The method of claim 14 wherein the method includes the step of: abrading the work piece with the article in a dry state prior to adding the liquid. 